Solid state lighting devices having improved color uniformity and associated methods

ABSTRACT

Solid state lighting (SSL) devices and methods of manufacturing SSL devices are disclosed herein. In one embodiment, an SSL device comprises a support having a surface and a solid state emitter (SSE) at the surface of the support. The SSE can emit a first light propagating along a plurality of first vectors. The SSL device can further include a converter material over at least a portion of the SSE. The converter material can emit a second light propagating along a plurality of second vectors. Additionally, the SSL device can include a lens over the SSE and the converter material. The lens can include a plurality of diffusion features that change the direction of the first light and the second light such that the first and second lights blend together as they exit the lens. The SSL device can emit a substantially uniform color of light.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/684,192, filed Apr. 10, 2015, which is a continuation of U.S. patentapplication Ser. No. 13/092,669, filed Apr. 22, 2011, now U.S. Pat. No.9,029,887, each of which is incorporated herein by reference in itsentirety.

TECHNICAL FIELD

The present technology is related to solid state lighting (“SSL”)devices and associated methods of manufacturing SSL devices. Inparticular, the present technology is related to SSL devices havinglenses that improve color uniformity across the SSL device andassociated methods.

BACKGROUND

Solid state lighting (“SSL”) devices generally use solid state emitters(“SSEs”) such as semiconductor light-emitting diodes (“LEDs”), organiclight-emitting diodes (“OLEDs”), and/or polymer light-emitting diodes(“PLEDs”) as sources of illumination rather than electrical filaments,plasma, or gas. A conventional type of SSL device has a “white light”SSE. White light requires a mixture of wavelengths to be perceived byhuman eyes. However, SSEs typically only emit light at one particularwavelength (e.g., blue light), so SSEs are modified to generate whitelight. One conventional technique for modulating the light from SSEsincludes depositing a converter material (e.g., phosphor) on the SSE.For example, FIG. 1 shows a conventional SSL device 10 that includes asupport 2, an SSE 4 attached to the support 2, and a converter material6 on the SSE 4. The SSE 4 emits light (e.g., blue light) radiallyoutward along a plurality of first vectors 8. The converter material 6scatters some of the light emitted by the SSE 4 and absorbs other lightemitted by the SSE 4. The absorbed light causes the converter material 6to emit light of a different color along a plurality of second vectors12. The light from the converter material along the second vectors 12can have a desired frequency (e.g., yellow light) such that thecombination of light along the first and second vectors 8 and 12 appearswhite to human eyes if the wavelengths and amplitudes of the emissionsare matched appropriately.

One challenge associated with conventional SSL devices (e.g., the SSLdevice 10 shown in FIG. 1) is that the color of light generally variesacross the SSL devices due to the emission angle. As shown in FIG. 1,when the SSE 4 is treated as a point source, the emission angle θ is theangle that light (e.g., along the first vectors 8) projects away from anaxis N normal to the support 2. The distance light travels through theconverter material 6 accordingly changes as a function of the emissionangle θ. As shown in FIG. 1, for example, the first vectors 8 havinggreater emission angles θ (e.g., 60°) travel greater distances throughthe converter material 6 than the first vectors 8 having smalleremission angles θ (e.g., 10°). The longer a first vector 8 travelsthrough the converter material 6, the more light from the SSE 4 theconverter material 6 absorbs, and the more light the converter material6 generates. As a result, light with a large emission angle θ andthereby a longer path through the converter material 6 includes lessblue light from the SSE 4 and generates more yellow light from theconverter material 6. Conversely, light with a small emission angle θand thereby a shorter path through the converter material 6 includesmore blue light from the SSE 4 and generates less yellow light from theconverter material 6. Therefore, when viewed head-on, the color of lightemitted by the SSL device 10 may appear more bluish, and when viewedfrom the side, the color of light may appear more yellowish.Accordingly, the emission angle θ of the light can result in colorvariance across the viewing angle of the SSL device 10.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional diagram of an SSL device inaccordance with the prior art.

FIG. 2A is a schematic cross-sectional view of an SSL device configuredin accordance with an embodiment of the present technology.

FIG. 2B is an operational view of the SSL device of FIG. 2A illustratingthe emission of light from the SSL device.

FIG. 3 is a graph showing the relationship between emission angles andcolor variations across SSL devices.

FIG. 4 is a flow chart showing a method of fabricating SSL devices inaccordance with an embodiment of the present technology.

FIG. 5A is a schematic cross-sectional view of an SSL device configuredin accordance with an embodiment of the present technology, and FIG. 5Bis a top plan view of the SSL device of FIG. 5A.

FIG. 6A is a schematic cross-sectional view of an SSL device configuredin accordance with another embodiment of the present technology, andFIG. 6B is a top plan view of the SSL device of FIG. 6A.

FIG. 7A is a schematic cross-sectional view of an SSL device, and FIGS.7B and 7C are top plan views of the SSL device of FIG. 7A configured inaccordance with further embodiments of the present technology.

FIG. 8 is a schematic cross-sectional view of an SSL device configuredin accordance with yet another embodiment of the present technology.

FIG. 9 is a schematic cross-sectional view of an SSL device configuredin accordance with an additional embodiment of the present technology.

DETAILED DESCRIPTION

Specific details of several embodiments of solid state lighting (“SSL”)devices and associated methods of manufacturing SSL devices aredescribed below. The term “SSL” generally refers to “solid state light”and/or “solid state lighting” according to the context in which it isused. The term “SSE” generally refers to solid state components thatconvert electrical energy into electromagnetic radiation in the visible,ultraviolet, infrared, and/or other spectra. SSEs include semiconductorlight-emitting diodes (“LEDs”), polymer light-emitting diodes (“PLEDs”),organic light-emitting diodes (“OLEDs”), or other types of solid statedevices that convert electrical energy into electromagnetic radiation ina desired spectrum. The term “phosphor” generally refers to a materialthat can continue emitting light after exposure to energy (e.g.,electrons and/or photons). Additionally, the term “lens” generallyrefers to a material (e.g., a transparent encapsulant) that can emitlight through its exterior surface. Packaged SSL devices and methods ofmanufacturing SSL assemblies are specifically described below to providean enabling disclosure, but the package and methods can be applied toany SSL device. A person skilled in the relevant art will understandthat the new technology may have additional embodiments and that the newtechnology may be practiced without several of the details of theembodiments described below with reference to FIGS. 2A-9.

FIG. 2A is a schematic cross-sectional view of an SSL device 200configured in accordance with an embodiment of the present technology.The SSL device 200 can include a support 202 and an SSE 204 attached toa surface 210 of the support 202. The SSL device 200 can further includea converter material 206 positioned over the SSE 204, and a lens 212positioned over both the SSE 204 and the converter material 206.

As shown in FIG. 2A, the SSE 204 can include a first semiconductormaterial 214, an active region 216, and a second semiconductor material218. The first semiconductor material 214 can be a P-type semiconductormaterial proximate a first side 208 a of the SSE 204, such as P-typegallium nitride (“P-GaN”), and the second semiconductor material 218 canbe an N-type semiconductor material proximate a second side 208 b of theSSE 204, such as N-type gallium nitride (“N-GaN”). This configuration issuitable for SSEs 204 formed on silicon growth substrates andsubsequently attached to the support 202. In other embodiments, such aswhen the SSE 204 is formed on a sapphire growth substrate, the P-GaN andN-GaN are reversed such that the P-GaN is proximate the second side 208b of the SSE 204 and the N-GaN is proximate the first side 208 a. Theactive region 216 can be indium gallium nitride (“InGaN”). The firstsemiconductor material 214, active region 216, and second semiconductormaterial 218 can be deposited sequentially using chemical vapordeposition (“CVD”), physical vapor deposition (“PVD”), atomic layerdeposition (“ALD”), plating, or other techniques known in thesemiconductor fabrication arts. In operation, the SSE 204 can emit afirst light in the visible spectrum (e.g., from about 390 nm to about750 nm), in the infrared spectrum (e.g., from about 1050 nm to about1550 nm), and/or in other suitable spectra.

As shown in FIG. 2A, the converter material 206 can be placed over atleast a portion of the SSE 204 such that light from the SSE 204irradiates the converter material 206. In the illustrated embodiment,the converter material 206 is positioned over a second side 208 b of theSSE 204 and is generally planar. In other embodiments, the convertermaterial 206 has a hemispherical or other suitable shape, and/or isspaced apart from the SSE 204 in other locations of the SSL device 200that are irradiated by the SSE 204. The irradiated converter material206 can emit a second light of a certain quality (e.g., color, warmth,intensity, etc.). For example, in one embodiment, the converter material206 emits yellow light. The second light emitted by the convertermaterial 206 can combine with the first light emitted by the SSE 204 togenerate a desired color of light (e.g., white light).

The converter material 206 can include a phosphor containing cerium(III)-doped yttrium aluminum garnet (YAG) at a particular concentrationfor emitting a range of colors from green to yellow and to red underphotoluminescence. In other embodiments, the converter material 206 caninclude neodymium-doped YAG, neodymium-chromium double-doped YAG,erbium-doped YAG, ytterbium-doped YAG, neodymium-cerium double-dopedYAG, holmium-chromium-thulium triple-doped YAG, thulium-doped YAG,chromium (IV)-doped YAG, dysprosium-doped YAG, samarium-doped YAG,terbium-doped YAG, and/or other suitable wavelength conversionmaterials. In further embodiments, the converter material 206 caninclude silicate phosphor, nitrate phosphor, aluminate phosphor and/orother types of salt or ester based phosphors.

As further shown in FIG. 2A, the lens 212 can be positioned over boththe converter material 206 and the SSE 204 such that light emitted bythe converter material 206 and the SSE 204 passes through the lens 212.The lens 212 can include a transmissive material made from silicone,polymethylmethacrylate (PMMA), resin, or other materials with suitableproperties for transmitting the radiation emitted by the SSE 204 and theconverter material 206. In selected embodiments, the lens 212 includesan additional converter material (not shown) that emits light at adifferent frequency than the converter material 206 proximate to (e.g.,the closest to) the SSE 204 to generate a desired color of light fromthe SSL device 200.

Additionally, as shown in FIG. 2A, the lens 212 can include a pluralityof diffusion features 226. For example, in the illustrated embodiment,the exterior surface of the lens 212 has a generally irregular orerratic complex curvature that forms the diffusion features 226. Inother embodiments, the diffusion features 226 can have different complexcurvatures and/or other suitable shapes. The diffusion features 226 candiffract or otherwise change the direction of light emitted by the SSE204 and the converter material 206 within the lens or as it exits thelens 212 to scatter the light. As described in more detail below, thescattered light can blend and/or otherwise diffuse the different colorsof light together such that the SSL device 200 emits a substantiallymore uniform color compared to a lens with a flat surface or uniformlyhemispherical surface.

FIG. 2B is an operational view of the SSL device 200 shown in FIG. 2Athat illustrates the emission of light from the SSL device 200. As shownin FIG. 2B, light can be emitted from the SSE 204 along a plurality offirst vectors 230 and from the converter material 206 along a pluralityof second vectors 232. For clarity, FIG. 2B shows only a portion of thelight emitted from the SSL device 200. The first and second vectors 230and 232 can be represented as projecting generally radially from the SSE204 and the converter material 206, respectively, as if they originatedfrom a point source. In operation, the first and second vectors 230 and232 project radially from all points across the face of the SSE 204. Inthe embodiment shown in FIG. 2B, for example, the SSE 204 and theconverter material 206 can emit the first and second vectors 230 and 232radially across a viewing plane of approximately 180°, stopping at thesurface 210 of the support 202. In other embodiments, the support 202can be configured such that viewing plane is wider or narrower.

As shown in FIG. 2B, the lens 212 can be sized large enough relative tothe SSE 204 such that the SSE 204 functions at least generally as apoint source. When the SSE 204 operates as a point source, the lens 212can have a generally circular base portion and at the surface 210 of thesupport 202 that corresponds to the radial projection of the light fromthe SSE 204. In other embodiments, such as when vertical height is aconstraint, the lens 212 can be smaller with respect to the SSE 204. Thebase of such a smaller lens 212 can have a shape that generallycorresponds to the shape of the SSE 204. In other embodiments, thesmaller lens 212 can have a shape that does not correspond to the shapeof the SSE 204.

As further shown in FIG. 2B, each first vector 230 projects away from anaxis 228 (i.e., an axis normal to the support 202) at an emission angleθ. The axis 228 corresponds with 0° such that the emission angle θ shownin FIG. 2B can range from vertical (0°) to horizontal (90° and −90°).First vectors 230 having larger emission angles θ travel longer pathsthrough the converter material 206. As light from the SSE 204 travelsthrough the converter material 206, the converter material 206 absorbssome of the light and generates light of a different color along thesecond vectors 232. Thus, larger emission angles θ increase the light(e.g., yellow light) emitted by the converter material 206 along thesecond vectors 232. Additionally, the converter material 206 scatterslight from the SSE 204. This can further increase the path length thatlight from the SSE 204 travels through the converter material 206, whichincreases the light absorbed by the converter material 206 and decreasesthe light (e.g., blue light) emitted by the SSE 204. Thus, the SSLdevice 200 emits more of a first color of light (e.g., blue light) fromthe SSE 204 along the first vectors 230 at a central portion of the SSLdevice 200 and more of a second color of light (e.g., yellow light) fromthe converter material 206 along the second vectors 232 at peripheralportions of the SSL device 200.

To mitigate such color nonuniformity, the diffusion features 226 of thelens 212 can diffract or otherwise change the direction of light fromthe first and second vectors 230 and 232 to other vectors that intersectand blend together as they exit the lens 212. The diffusion features 226can accordingly scatter light along irregular or erratic vectors at thesurface of the lens 212. For example, the diffusion features 226 can beconfigured at different angles relative to the SSE 204 and/or thesubstrate 202 such that light along the first vectors 230 with a higheremission angles θdiffract or otherwise change direction toward the axis228 and intersect with light from the second vectors 232 and/or firstvectors 230 with lower emission angles θ. As light from the first andsecond vectors 230 and 232 intersect, their respective colors cancombine to generate a generally uniform color across the SSL device 200.

In the embodiment illustrated in FIG. 2B, the diffusion features 226 ofthe lens 212 diffract or otherwise change the direction of the first andsecond vectors 230 and 232 in random, irregular, or generally erraticdirections. In other embodiments, the lens 212 can change the directionof light such that light from the first and second vectors 230 and 232intersects in a particular pattern to provide a desired lightdistribution. For example, the diffusion features 226 of the lens 212can be configured to collimate the light emitted by the SSL device 200,project the light emitted by the SSL device 200 at a wide angle (e.g.,toward the periphery of the SSL device 200), and/or emit light in othersuitable light distributions.

FIG. 3 is a graph showing the relationship between emission angles θ andcolor variations duv across SSL devices. The graph includes a firstcurve 334 that illustrates the color variation across a conventional SSLdevice. The first curve 334 shows that increasing the emission angle θvaries the color of light emitted across the conventional SSL device. Asa result, the peripheral portions of the conventional SSL device emitmore light (e.g., yellow light) from the converter material, while thecentral portion of the conventional SSL device emits more light (e.g.,blue light) from the SSE. Accordingly, the conventional SSL device emitsa nonuniform color of light.

The graph of FIG. 3 also has a second curve 336 that illustrates thecolor variation across an SSL device configured in accordance withselected embodiments of the present technology (e.g., the SSL device 200described above with reference to FIGS. 2A and 2B). As shown in FIG. 3,the second curve 336 is generally flat irrespective of variations in theemission angle θ. As described above, diffusion features of a lens(e.g., the diffusion features 226 of the lens 212 shown in FIGS. 2A and2B) can diffract and blend light as it exits the lens to mitigate colorvariance caused by the emission angle θ. Accordingly, many embodimentsof SSL devices configured in accordance with the present technology areexpected to provide superior color uniformity across the viewing plane.

FIG. 4 is a flow chart of a method 400 for fabricating SSL devices inaccordance with an embodiment of the present technology. The method 400can include positioning SSEs on a surface of a support wafer (block402). The SSEs and the support wafer can be generally similar to the SSE204 and the support 202 described above with reference to FIGS. 2A and2B. The SSEs can be positioned on the support wafer using surfacemounting and/or other suitable methods for attaching SSEs on supports.In other embodiments, the support wafer can comprise a material thatencourages epitaxial growth such that the SSEs can be formed directly onthe support wafer.

The method 400 can further include positioning a converter material overeach of the SSEs (block 404). The converter material can be phosphorand/or other converter materials generally similar to the convertermaterial 206 described with reference to FIG. 2A. The converter materialcan be placed over the SSEs using CVD, PVD, and/or other suitablemethods for depositing converter material on the SSEs. The convertermaterial may be positioned anywhere where light from the correspondingSSE can irradiate energized particles (e.g., electrons and/or photons)in the converter material. In selected embodiments, the convertermaterial can be applied in discrete sections over individual SSEs.

The method 400 can continue by positioning a lens over one or more ofthe SSEs (block 406). In several embodiments, the lenses can be formedover the SSEs. For example, during overmolding, a mold can be filledwith a lens material (e.g., silicone, epoxy, and/or another suitablytransparent lens material) and placed over at least one SSE such thatthe lens material encapsulates the SSE and the corresponding convertermaterial. The mold can be compressed, heated, and/or otherwise processedto harden the lens material and attach the lens to the support wafer. Inother embodiments, the lens is injection molded over one or more SSEs byplacing a mold over the SSE(s) and injecting the lens material into themold at elevated temperatures and pressures. In further embodiments, thelens is formed separately from the SSEs, placed over the SSEs, andattached to the support wafer. Once the lenses are positioned over theSSEs and the converter material, the method 400 can include singulatingindividual SSL devices between the lenses (block 408). In selectedembodiments, the SSEs are singulated before the lenses are positionedover the SSEs. In other embodiments, the SSEs are singulated even beforethe converter material is deposited on the SSEs. The singulated SSLdevices can emit a substantially uniform color of light.

FIG. 5A is a schematic cross-sectional view of an SSL device 500configured in accordance with an additional embodiment of the presenttechnology, and FIG. 5B is a top plan view of the SSL device 500.Several features of the SSL device 500 are generally similar to thefeatures of the SSL device 200 shown in FIGS. 2A and 2B. For example,the SSL device 500 includes the support 202, the SSE 204, and theconverter material 206. In the embodiment illustrated in FIGS. 5A and5B, the SSL device 500 includes a lens 512 that has diffusion features526 that are symmetric relative to a central axis C-C. As shown in FIG.5A, the diffusion features 526 can be concentric shoulders, steps orridges in the lens 512. In other embodiments, the lens 512 can includemore or less ridges and/or can have other shapes symmetric with respectto the central axis C-C. Similar to the diffusion features 226 shown inFIGS. 2A and 2B, the diffusion features 526 of the SSL device 500 changethe direction of light as it exits the lens 512 such that light emittedfrom the SSE 204 intersects with itself and light emitted by theconverter material 206. Accordingly, the lens 512 can blend differentcolors of light from the SSE 204 and the converter material 206 toreduce the color variance across the SSL device 500. Additionally, asshown in FIGS. 5A and 5B, the lens 512 can be large relative to the SSE204 such that the SSE 204 functions effectively as a point source.Accordingly, as shown in FIG. 5B, the lens 512 can have a generallycircular base portion at the surface 210 of the support 202 and astepped dome-like shape that corresponds to the radial projection oflight emitted by the SSE 204.

FIGS. 6A and 6B are a schematic cross-sectional view and a top planview, respectively of an SSL device 600 in accordance with anotherembodiment of the present technology. Several features of the SSL device600 are generally similar to the features of the SSL device 500 shown inFIGS. 5A and 5B. For example, the SSL device 600 includes the concentricridges that form the diffusion features 526. The SSL device 600 includesa lens 612 shaped generally similar to the shape of the SSE 204. In theembodiment illustrated in FIG. 6B, for example, the SSE 204 has arectangular shape and the lens 612 has a corresponding rectangularshape. In other embodiments, the lens 612 has a different shape (e.g.,square, oval) corresponding to the shape of the SSE 204. Thecomplimentary shape of the lens 612 allows the lens 612 to be smallerthan domed or hemispherical lenses. The smaller lens 612 shown in FIG. 6can be used in applications with space constraints and/or when the sizeof the SSE 204 requires the lens to have a low vertical profile (e.g.,long lights).

FIG. 7A is a schematic cross-sectional view of an SSL device 700 inaccordance with yet another embodiment of the present technology, andFIGS. 7B and 7C are top plan views of the SSL device 700 of FIG. 7A.Several features of the SSL device 700 are generally similar to thefeatures of the SSL devices 200, 500 and 600 shown in FIGS. 2A, 2B,5A-6B, and are accordingly not described in detail below. As shown inFIGS. 7A-C, the SSL device 700 can include a lens 712 having a pluralityof diffusion features 726 in the form of depressions. For example, thediffusion features 726 can be dimples as shown in FIG. 7B and/orconcentric grooves as shown in FIG. 7C. In other embodiments, thediffusion features 726 can be other suitable depressions and/or thedepressions can change over different portions of the lens 712. Similarto the lenses described above, the diffusion features 726 of the lens712 shown in FIG. 7A-C can scatter light as it exits the lens 712 toblend different colors of light into a substantially uniform coloracross the SSL device 700.

As further shown in FIGS. 7A-C, the lens 712 can be positioned over aplurality of SSEs 204 at the surface 210 of the support 202. Referringto FIG. 7A, the converter material 206 can be placed on a front side ofeach SSE 204 in discrete segments (e.g., wafer level converter material206). In other embodiments, the converter material 206 can cover moresurfaces of the SSEs 204. In further embodiments, the converter material206 can be deposited over the plurality of SSEs 204 in a single layer.In still further embodiments, some of the SSEs 204 may be exposed ratherthan covered by the converter material 206. For example, the SSEs 204 atthe peripheral portion of the SSL device 700 may not be covered with theconverter material 206 such that light emitted from the SSEs at the sideof the SSL device 700 is not altered by the converter material 206. Inadditional embodiments, the converter material 206 can be spaced apartfrom the SSE 204 in a location that is still irradiated by the SSE 204.

In the embodiment shown in FIGS. 7A-7C, the lens 712 has a hemisphericalshape and is large enough that the SSEs 204 act effectively as pointsources. In other embodiments, the lens 712 can have a shape that atleast generally corresponds to the shape the SSEs 204. For example, theSSEs 204 can be arranged in a rectangular array across the surface 210of the support 202, and the lens 712 can have a generally rectangularbase portion at the surface 210 of the support 202 corresponding to theshape of the array.

FIG. 8 is a schematic cross-sectional view of an SSL device 800 inaccordance with a further embodiment of the present technology. Severalfeatures of the SSL device 800 are generally similar to the features ofthe SSL devices described above. For example, as shown in FIG. 8, theSSL device 800 can include a lens 812 that has a plurality ofprotrusions that form a plurality of diffusion features 826. Thediffusion features 826 can change the direction of light as it exits thelens 812 to blend different colors of light together and therebymitigate the color nonuniformity caused by the emission angle. The SSLdevice 800 shown in FIG. 8, however, does not include a layer ofconverter material covering the SSE 204. Rather, the lens 812 caninclude the converter material 0606. In the embodiment illustrated inFIG. 8, for example, the converter material 206 is distributedthroughout the lens 812. In other embodiments, the converter material206 is localized in specific regions within the lens 812. For example,the converter material 206 can be positioned in a central portion of thelens 812 such that the light emitted from the SSE 204 at the peripheralportions of the lens 812 is not altered by the converter material 206.In other embodiments, the lens 812 can include a plurality of differentconverter materials 206 localized in specific regions within the lens812 to emit light with different wavelengths.

FIG. 9 is a schematic cross-sectional view of an SSL device 900configured in accordance with an additional embodiment of the presenttechnology. Several features of the SSL device 900 are generally similarto the features of the SSL devices shown above. The SSL device 900,however, includes two lenses. As shown in FIG. 9, a first lens 938 canbe over the SSE 204 and a converter material 906 can be on the firstlens 938. The converter material 906 can be at least generally similarto the converter material 206 described above with reference to FIGS. 2Aand 5A-7C. As further shown in FIG. 9, a second lens 912 can bepositioned over and/or around the first lens 938 and the convertermaterial 906. The second lens 912 can be at least generally similar tothe lenses having diffusion features described above with reference toFIGS. 2A, 2B and 5A-8. For example, the second lens 912 can have aplurality of irregular diffusion features 926 that scatter light as itexits the second lens 912 to mitigate color variance caused by theemission angle. In selected embodiments, the second lens 912 can be usedto retrofit an existing SSL device that includes the first lens 938 toincrease the color uniformity of the existing SSL device.

From the foregoing, it will be appreciated that specific embodiments ofthe technology have been described herein for purposes of illustration,but that various modifications may be made without deviating from thedisclosure. For example, the SSL devices shown in FIGS. 2A and 5A-7Cinclude converter material 206 having a generally rectangularcross-sectional shape. However, in other embodiments, the convertermaterial 206 can have a different cross-sectional shape (e.g.,semicircular, irregular) or be incorporated into the lenses.Additionally, lenses in accordance with the present technology can havedifferent shapes than those shown in the Figures. For example, a lenscan have any shape that changes the direction of the light as it exitsthe lens to blend different colors of light together. Certain aspects ofthe new technology described in the context of particular embodimentsmay be combined or eliminated in other embodiments. For example, the SSLdevices shown above can include both a converter material over an SSE asshown in FIGS. 2A, 5A-7C and 9 and a second converter materialdistributed throughout a lens as shown in FIG. 8. Additionally, whileadvantages associated with certain embodiments of the new technologyhave been described in the context of those embodiments, otherembodiments may also exhibit such advantages, but not all of theembodiments within the scope of the technology necessarily exhibit suchadvantages. Accordingly, the disclosure and associated technology canencompass other embodiments not expressly shown or described herein.

We claim:
 1. A method of manufacturing a solid state lighting (SSL)device, comprising: positioning a solid state emitter (SSE) on a surfaceof a support, the support having a centerline axis projecting normal tothe surface; wherein the solid state emitter has a first side and asecond side opposite the second side, the first being at the surface ofthe support; positioning a first lens over the SSE; covering at least aportion of the second side of the SSE a with a converter material; andpositioning a dome-shaped second lens over the SSE, the first lens, andthe converter material, the second lens having a plurality of diffusionfeatures, wherein, in operation, the SSE emits a first light propagatingaway from the surface of the support along a plurality of first vectors,the converter material emits a second light propagating along aplurality of second vectors, and wherein the plurality of diffusionfeatures are configured to change the direction of the first light andthe second light propagating along the first and second vectors,respectively, such that the first light and the second light blendtogether as they exit the second lens, wherein an exterior surface ofthe second lens has an irregular or erratic complex curvature and thediffusion features are formed in a random pattern, and wherein thediffusion features are configured at different angles relative to theSSE such that the second propagating light propagating along the secondvectors at an emission angle θ changes direction away from the centerline axis and intersects with the second light propagating along thesecond vectors having an emission angle greater than θ and with thefirst light propagating along the first vectors away from the centerline axis.
 2. The method of claim 1 wherein positioning the second lenscomprises at least one of injection molding and overmolding the secondlens over the SSE, the first lens, and the converter material.
 3. Themethod of claim 1 wherein positioning the second lens comprises: formingthe second lens separately from the SSE; and attaching the second lenson the surface of the support after the second lens is formed.
 4. Themethod of claim 1 wherein positioning the second lens comprises: sizingthe second lens large enough relative to the SSE such that the SSEfunctions effectively as a point source; and forming a base portion ofthe second lens, the base portion being proximate to the surface of thesupport, wherein the base portion has a generally circular shape.
 5. Themethod of claim 1 wherein positioning the second lens comprises: forminga base portion of the second lens, the base portion being proximate tothe surface of the support, wherein the base portion has a shape atleast generally corresponding to a shape of the SSE at the surface ofthe support.